Remove/install rail - AR07.03-P-1010MMB

ENGINE 157, 278 in MODEL 216, 221 

Shown on model 221.073 

Fig 1: Identifying Rail Remove/Install Components - Shown On Model 221.073

Courtesy of MERCEDES-BENZ USA

	Risk of injury  caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.	No parts of the body or limbs should be within the operating area when the components are moving.	AS00.00-Z-0011-01A
	Risk of explosion  caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel.	No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
	General information on work on gasoline direct injection system		AH07.00-P-2000-01A
	Remove
1	Detach ground line from battery		AR54.10-P-0003SX
	Notes on battery		AH54.10-P-0001-01A
2	Remove upper engine covers
3	Remove air filter housing
4	Remove insulation on rail (1)
5	Remove ME-SFI [ME] control unit		AR07.08-P-7008MMB
6	Disconnect electrical connection at fuel pressure and temperature sensor	When removing the right rail (1)
7	Detach engine wiring harness from rail (1) and fuel injectors (Y76)		AR01.00-P-2410-02MMB
8	Relieve fuel pressure over diagnostic socket		AR07.03-P-1460-01VA
		Protective cap on service valve	*BA07.03-P-1007-01E
		Pressure hose	Figure
9	Remove fuel pressure in fuel high-pressure circuit		AR07.03-P-1460-02MM
10	Remove high-pressure lines for high-pressure pumps on rails (1)	Do not kink or bend high-pressure lines. This is to avoid leaks and damage if the high-pressure lines are possibly used again (after successfully passing checking).
11	Remove high-pressure line between rails (1)	Do not kink or bend high-pressure lines. This is to avoid leaks and damage if the high-pressure lines are possibly used again (after successfully passing checking).
12	Remove screws/bolts (1s)	Remove screw/bolts (1s) for removal of the rail (1) alternately by respectively turning half a revolution from the center outwards. Damage to the rail (1) can occur otherwise.
13	Remove hold-down tool (3) between rail (1) and fuel injectors (Y76)
14	Mark fuel injectors (Y76) relative to the respective cylinder	When reusing the fuel injectors (Y76) they must be inserted into the cylinder in which it was previously installed.
15	Detach rail (1) from fuel injectors (Y76)
16	Remove fuel injectors (Y76)		AR07.03-P-0004MMB
		Oil which comes out during disassembly of the rail (1) or from the fuel injectors (Y76) is safe. The rail (1) or the fuel injectors (Y76) can be re-used. Fuel injectors (Y76) must  be pulled out, since the rail (1) only together  with the fuel injectors (Y76) may be installed. In case of jammed fuel injectors (Y76): ↓ Remove injection nozzle.
			AR07.03-P-0004-03MM
		Puller	Figure
	Clean
17	Clean fuel connections on fuel injectors (Y76)	During cleaning the fuel connections must be held downwards. Dirt will get into the openings otherwise.
	Check
18	Check high-pressure line and replace if necessary		AR07.03-P-1010-03MM
		The sealing cone for high-pressure lines must be checked before assembly. Do this to avoid leaks and damage.
		Assembly cleaner	*BR00.45-Z-1028-04A
	Install
19	Replace sealing packages for the fuel injectors (Y76) on rail (1)		AR07.03-P-0004-02MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Drift	Fig 2
20	Replace sealing rings and seal at fuel injectors (Y76)		AR07.03-P-0004-01MM
		Assembly cleaner	*BR00.45-Z-1028-04A
		Assembly tool	Figure
21	Replace seal (2) on spilling of the rail (1)
22	Put fuel injectors (Y76) into rail (1) and fasten in place using the hold-down tools (3)	When reusing the fuel injectors they (Y76) must be inserted into the cylinder in which it was previously installed. Fuel injectors (Y76) may only be installed again in combination with the rail (1) (as a whole). Replace hold-down tool (3).
23	Insert rail (1) with fuel injectors (Y76) into the cylinder head
24	Screw in screw/bolts (1s)	Screw in screw/bolts (1s) alternately each by half a revolution. Begin in the middle of the rail (1) and work outwards. Damage to the rail (1) can occur otherwise.
		Screw/bolt, fuel distributor to cylinder head cover	*BA07.52-P-1001-01G
25	Mount high-pressure line on rail (1) and high-pressure pump		AR07.03-P-1010-02MMB
		Do not kink or bend high-pressure lines. Otherwise leaks and damage may occur. The work instructions absolutely must be observed for assembly work.
		Union nut, fuel line to fuel distributor	*BA07.03-P-1001-01E
		Union nut, fuel line to high-pressure pump	*BA07.03-P-1002-01E
		Bolt, fuel line service valve to cylinder head cover	*BA07.03-P-1003-01E
		Bolt, right bracket for fuel line clamp to high pressure pump drive housing/cylinder head	*BA07.03-P-1004-01E
		Bolt, left bracket for high pressure line clamp to cylinder head cover/cylinder crankcase	*BA07.03-P-1005-01E
		Bolt, fuel line clamp to charge air distribution line	*BA07.03-P-1006-01E
		Fuel line union nut on service valve	*BA07.03-P-1008-01E
26	Mount engine wiring harness from rail (1) and fuel injectors (Y76)		AR01.00-P-2410-02MMB
27	Connect electrical connection at fuel pressure and temperature sensor	When removing the right rail (1)
28	Install ME-SFI [ME] control unit		AR07.08-P-7008MMB
29	Install insulation on rail (1)
30	Install air filter housing
31	Install upper engine covers
32	Mount ground line on battery		AR54.10-P-0003SX
	Notes on battery		AH54.10-P-0001-01A
33	Read out fault memory using the diagnostic system and clear if necessary
			AD00.00-P-2000-04A
	Check
34	Check fuel high-pressure circuit for leaktightness.		AR07.03-P-1010-04MM
	Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
35	Perform an engine test run; in doing so check engine for proper operation and leaktightness

Fig 2: Identifying Drift (278 589 01 15 00)

Courtesy of MERCEDES-BENZ USA

Fig 3: Identifying Pressure Hose (119 589 04 63 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Puller (278 589 00 33 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Assembly Tool (272 589 00 43 00)

Courtesy of MERCEDES-BENZ USA